Innerspring mattress with plastic foam cover



Aug. 17, 1965 w. LEBE-:Ns 3,200,418

INNEHSPRING MATTRESS WITH PLASTIC FOAM COVER Filed NOV. 2, 1951 2- Sheets-Sheet l Aug. 17, 1965 w. LEBENS 3,200,418

INNERSPRING MATTRESS WITH PLASTIC'FOAM COVER Filed NOV. 2, 1961 2 Sheets-Sheet 2 M IN VEN TOR.

United States Patent O 3,200,418 INNERSPRENG MATTRESS WITH PLASTIC FAM CVER Wiihelm Lebens, Lenchtenburg, Germany Filed Nov. 2, 1961, Ser. No. 150,118 2 Claims. (Cl. 5-351) The present invention re'lates to means and method of makin-g .an improved mattress, in particular lto innerspring mattress having a cover layer of resilient material for maintaining long lasting form and a desired degree of elasticity of `the mattress.

it has been known to manufacture mattresses of .'plastic foam .or other resilient lightweight materials. Such known mattresses had the disadvantage of 'being not porous enough to maintain a desired degree of ventilation after compression and further on account of their limited range of elasticity, an additional spring mattress of higher elasticity range had to be used.

It has also been known to cover both sides of the mattress with a plastic foam layer being approximately the size of lthe top and bottom parts of the mattress and to maintain the layer in position. Attempts have been made to shape the layer in the for-m of a cap enclosing the innerspring structure olf the mattress, however, the disadvantage remained in the costly and complicated process of manufacture. Another disadvantage could be found in the known -type of matttresses Iusing plastic foam covers that in maintaining the oam sheet in position on the spr-ing frame of the mattress, the edges of the foam :sheet were bent and glued together whereby a further disadvantage existed in that the vertical movement of the springs and thereby the inwardly bending edges of the foam cover were clamped in the springs and so causing .a rapid wear-out orf the mattress.

The present invention .aims to obviate the above mentioned disadvantages whereby a novel combinationof an innerspring mattress together with a sheet of resilient foam material is utilized.

It is an object of the present invention to provide for a mattress of the innerspring mattress type having Va cover iayer of resilientmateria'l which is simple in construction and economical t-o manufacture.

IIt is another object to provide for a mattress combining the advantages of the innerspring mattress with those of the foam mattress type.

It is also an object of the invention to provide for a mattress of the character indicated that is Ilight in weight and at the same time maintaining the elasticity of the innerspring mattress and softness of a plastic -foam mat- .tress without eiecting the elasticity `of the mattress itself.

These and other object :and advantages of 'the present invention `will Ibe more clearly understood when considered in conjunction with the accompanying drawings in which FIG. l is a perspective view of a mattress embodying the invention,

FIG. 2 is an enlarged part-sectional view showing the fixing of the intermediate layer, as is shown in FIG. 1,

FIG. 3n is a lperspective view yof a mattress iilling machine,

FIG. 4 is a cross-sectional view tot the mattress showing the overlapping edges of the plastic foam sheet prior to bending by side-'walls of the iilling machine,

FIG. 5 is a cross-sectional view of the mattress in its compressed iorm prior to tiilling into its ticking,

yFiG. 6 is .an enlarged cross-sectional view of `a mattress after having been iilled into its ticking, `and FIG. 7 is an enlarged part-sectional yView of It-he mattress with modification embodying the invention.

Referring .frst to lFIG. l the mattress :there illustrated comprises spring frame 3 and springs 1, together form- ICC ing the innerspring mattress structure of known construction, on iboth sides of which a thin intermediate layer 2 of rubberized iiibrous material, such as animal hair, coi-r iiber, palm iiber, sisal iiber is positioned which is turther covered with a llayer `5, 5 of resilient foam material, such as plastic lfoam. 'Iihe width of the overlapping edges of plastic iOam sheet 5a' is substantially equal on all sides. The :angular :slot provided at each corner of the `foam sheet will form after bending the respective overlapping edges an even corner of the mattress.

The `slightly .overlapping edges of :intermediate 4layer 2 Vare ebent under the spring frame 3, as shown in FIG. 2, and held in position by clips r4. As the nphoistering of the innerspring structure is carried out on both sides, it 'gives an obvious way for a mattress ot both-sided use. When intermediate layer is in position, it is lcomparatively an easy operation to glue plastic toam sheets 5, y5 to said llayer thereby maintaining foam sheet `S 'in a hxed position without imparting any lo-ss to the elasticity of the actual mattress.

The mattress filling :machine 6 in IFIG. 3 is used to complete the fiilling operation of the mattress -by compressing :and filling said mattress into `its ticking 15.

Since yother types :of mattress iiilling machines may he used for the hlling operation of mattresses, the description herewith given relating to the side-wall type iilling machine is only exemplary to illustrate one form of iilling procedure embodying the invention.

When the preparatory upholstering work of the innerspring structure is completed, then the mattress is ready for the filling into its ticking. The iilling machine employed for this purpose is shown in FIG. 3 of known type having parallel folding side walls together with locking devices being actuated by lever 3, a rotatable press cover 1i) comprising counter weight 16 for balancing said cover, driving mechanism (not shown) for the actuation of filling spoon 11, the shape of which is suited to the size of the mattress and a locking device 1S and 17 for keeping press cover 10 in position during the lling operation.

As shown in FIG. 4 the opened side walls 7 of the lling machine 5 form a trough-like space into which the mattress can be easily inserted. By closing side-wall '7 in direction of arrow B, the overlapping edges of lower plastic foam sheet 5 will be bent into position and simultaneously the overlapping edges of upper plastic foam sheet 5 are bent manually in direction of arrow A to hold in position said edges by closed side walls 7, as shown in FIG. 3. The rear end of the overlapping edges facing the filling spoon 11 is eiected in the same manner as the sides by manually bending said edges in contact with the iilling spoon 11.

It is a distinctive feature of the present invention for filling mattresses that to make possible the smooth conveying of mattress into its ticking and to reduce the friction between the plastic foam sheet and the enclosing inner surfaces of the illing machine, there is provided a thin layer 12 of material oi antifriction nature, such as cotton wool, synthetic iiber or a powder of the same nature, as shown in FIG. 4, covering the whole outer surface of plastic foam sheet 5.

It is now possible by this arrangement that the mattress even under compression will be carried neatly into its ticking 1S, in direction of arrow D as shown in FG. 5. The conventional type mattresses employing a thick layer of upholstering over the surface to be contact with the ticking have the disadvantage that after certain time of use the thick layer will lose its elasticity and will show an unporous layer with the further disadvantage, as previously described.

Before closing press cover iii, gate 14 is raised to the height ot the mattress to which gate the mattress is advanced and thereby the front overlapping edges of the plastic foam sheet are bent in position in similar manner as the side edges shown in FIG. 5. After pulling down press cover 10, which is easily shut by means of a handwheel 21, in FIG. 3, gate 14 is lowered to give free way for the advancing mattress which is moved forward by filling spoon 11. Before commencing the actual filling a ready sewn ticking is pulled over the front end of closed press cover l and bottom guide walls 9, as shown in FIG. 5. By withdrawing gate 14 in direction of arrow C the overlapping front edges of plastic foam sheet will occupy their initial horizontal position, however, on advancement of the mattress further in contact with the ticking 15, said overlapping edges will be folded into their bent-in position prior of opening gate 14. Thus, it may be observed that the mattress is carried neatly into its ticking by the filling spoon l1 without ramming or stufhng. Since the advancing mattress is carried by the filling spoon Il right into its ticking and by terminating the movement of said filling spoon only when the ticking is fully filled, it will maintain a tight form of the mattress on account of the relieved compression of the innerspring structure leaving the lling machine 6.

When filling is completed, the spoon 11 returns to its initial position and the machine stops automatically. A work-bench 19 is provided for accepting the advancing and completely filled mattress. After the filling operation the rear end of the mattress is sewn together thereby maintaining the bent-in edges in their intended position,

FIG. 6 is a cross-sectional view of an innerspring mattress with plastic foam covering according to the invention showing the respective layers in position as described above. The height chosen for the innerspring structure will be in accordance with the required depth of the bed, which in most cases is 16 cm. The rubberized intermediate layer 2 covering innerspring structure may have a thickness of 3 4 providing a sufiicient overall strength for evenly distributing the adjacently acting individual spring forces of the innerspring structure. The metal frame and the continuously wound coil springs may have an anti-rust coating to maintain a clean interior and elasticity of the mattress. Since the individual spring forces have been evenly distributed by intermediate layer 2, the covering plastic foam sheets, 5, 5 may have a reduced thickness in the range of -30 mm. The intermediate layer 2 preferably may have a weight of 450-500 g./m.2. If this weight is increased, the result will be a mattress with higher stiffness and if it is reduced, a mattress with less stiffness will result.

The layer 12 provided for the easy conveying of mattress into its ticking may have a thickness of 1 mm. or less. It may be omitted, if the outer surface of resilient foam material 5 is provided i.e. with an impregnated layer of antifriction nature for the smooth sliding of said mattress.

The width of the overlapping part of the plastic foam sheet 5 is chosen in such a manner that after bending the top and bottom foam layer, there is a gap d provided all around the sides of the mattress, which gap further means a space in which the up and down movement of the plastic foam cover edge can take place without any jamming or clamping by springs 1 of the innerspring structure.

In FIG. 7 there is shown in part-section an innerspirng mattress with plastic foam cover being identical with that of FIG. 6 and in addition showing ticking 15a into which the mattress is compressed and filled in the manner as described and by retaining the original ticking 15 which in this arrangement is made to be easily changeable for replacement or for cleaning. This embodiment as shown in FlG. 7 is particularly advantageous for medical purposes whereby the mattress can be used on both sides which is hygenic in use. After use the outer ticking 15 may be pulled off, and the inner ticking 15a together with `the innerspring structure may be put into a disinfectant bath provided the metal parts are made of rust-proof material or have an anti-rust coating. In general the material for the inner cover ticking 15a may be of nettle fiber and the material for the outer ticking 15 may be of any durable textile, preferably being of reinforced cotton nature.

What I claim is:

1. A reversible, long-life innerspring mattress having goed form retention and a selected degree of softness, said mattress comprising,

an interconnected coil spring assembly having an outer surface, a lower surface and a continuous outer side edge,

an upper and lower fibrous material layer covering said upper and lower surfaces respectively and each having marginal portions bent over and attached to said coil spring assembly, an upper and lower resilient, substantially planar foam material layer covering said upper and lower fibrous material layers respectively and each having a free peripheral portion thereof extending beyond said outer side edge of the mattress, said peripheral portion of said upper foam layer being overturned toward said lower foam layer at said side edge and said peripheral portion of said lower foam layer being overturned toward said upper foam layer at said side edge with said overturned portions of said upper and lower foam layers defining ends spaced from and substantially facing each other,

an upper and lower anti-friction layer covering said upper and lower resilient foam material layers respectively,

said foam layers having corners defining angular slots therein positioned adjacent corners provided by said assembly,

and said assembly and all said layers being encased in an outer ticking which solely maintains said folded over ends of said foam layers in their intended position.

2. A reversible long-life innerspring mattress in accordance with claim 1 wherein said resilient foam material layers are adhered to said fibrous material layers.

References Cited by the Examiner UNITED STATES PATENTS 2,726,977 12/55 See et al 5-361 X 2,800,165 7/59 Talalay et al. 5-361 X 2,887,693 5/59 Hodges 5 351 2,975,437 3/61 Freeman 5-351 3,005,021 9/62 Rymland 5 351 3,056,245 10/62 Baum et al. 53-24 3,059,387 10/62 Fasanella 53-24 FRANK B. SHERRY, Primary Examiner.

GEORGE L. BREHM, CHANCELLOR E. HARRIS,

Examiners. 

1. A REVERSIBLE, LONG-LIFE INNERSPRING MATTRESS HAVING GOOD FORM RETENTION AND A SELECTYED DEGREE OF SOFTNESS, SAID MATTRESS COMPRISING, AN INTERCO NNECTED COIL SPRING ASSEMBLY HAVING AN OUTER SURFACE, A LOWER SURFACE AND A CONTINUOUS OUTER SIDE EDGE, AN UPPER AND LOWER FIBROUS MATERIAL LAYER COVERING SAID UPPER AND LOWER SURFACES RESPECTVELY AND EACH HAVING MARGINAL PORTIONS BENT OVER AND ATTACHED TO SAID COIL SPRING ASSEMBLY, AN UPPER AND LOWER RESILIENT, SUBSTANTIALLY PLANAR FOAM MATERIAL LAYER COVERING SAID UPPER AND LOWER FIBROUS MATERIAL LAYERS RESPECTIVELY AND EACH HAVINGA FREE PERIPHERAL PORTION THEREOF EXTENDING BEYOND SAID OUTER SIDE EDGE OF THE MATTRESS, SAID PERIPHERAL PORTION OF SAID UPPER FOAM LAYER BEING OVERTURNED TOWARD SAID LOWER FOAM LAYER AT SAID SIDE EDGE AND SAID PERIPHERAL PORTION OF SAID LOWER FOAM LAYER BEING OVERTURNED TOWARD SAID UPPER FOAM LAYER AT SAID SIDE EDGE WITH SAID OVERTURNED PORTIONSO F SAID UPPER AND LOWER FEOAM LAYERS DEFINING ENDS SPACED FROM AND SUBSTANTIALLY FACING EACH OTHER, AN UPPERAND LOWER ANTI-FRICTION LAYER COVERING SAID UPPER AND LOWER RESILIENT FOAM MATERIAL LAYERS RERESPECTIVELY, SAID FOAM LAYERS HAVING CORNERS DEFINING ANGULAR SLOTS THEREIN POSITIONED ADJACENT CORNERS PROVIDED BY SAID ASSEMBLY, AND SAID ASSEMBLY AND ALL SAID LAYERS BEING ENCASED IN AN OUTER TICKING WHICH SOLELY MAINTAINS SAID FOLDED OVER ENDS OF SAID FOAM LAYERS IN THEIR INTENDED POSITION. 